ALFA 5KVA Service Manual 201509A
ALFA 5KVA Service Manual 201509A
ALFA 5KVA Service Manual 201509A
Service manual
1
V201505A
Table of contents
1. General information .............................................................................................................................................. 3
1.1 Getting start ................................................................................................................................................. 3
1.2 Basic topology introduction ....................................................................................................................... 3
1.3 Overview the inverter ................................................................................................................................. 4
2. Troubleshooting .................................................................................................................................................... 5
2.1 How to do..................................................................................................................................................... 5
2.2 Fault condition............................................................................................................................................. 5
2.3 Test step....................................................................................................................................................... 8
3. Checking and measuring guide ........................................................................................................................ 12
3.1 Check the battery side components ...................................................................................................... 12
3.2 Check the bus side components ............................................................................................................ 18
3.3 Check the buck circuit.............................................................................................................................. 20
3.4 Check the INV full bridge ........................................................................................................................ 22
3.5 Check the bus soft start circuit (TX2: Especially for 09 fault) ............................................................ 24
3.6 Check the AC switching power supply circuit....................................................................................... 26
3.7 Check the battery switching power supply circuit ................................................................................ 28
3.8 Check the reversed protection MOSFETs on DC side ....................................................................... 31
3.9 Check the current sharing module of control board ............................................................................ 33
3.10 Check the NTC circuit............................................................................................................................ 34
3.11 Check the fan driver on the main board .............................................................................................. 38
4. Assembling guide ............................................................................................................................................... 39
2
V201505A
1. General information
1.1 Getting start
This manual is used as a checking and repairing guide for INVERTER PWM&MPPT 4KVA/5KVA. Before
read this manual, it’s best to have some electrical or electronic background knowledge. With this guide,
you can fix the inverter by yourself firstly.
There are four main parts of this guide:
General information: This part is the basic information of the inverter; you can start to know the inverter
from this chapter.
Troubleshooting: This part will tell you how to do when you face a problem.
Checking and measuring guide: This part will teach you how to check or repair the inverter by
measuring the critical components.
Assembling guide: This part teaches you how to take the board outside and fix the new one.
Utility
CNTL board
Control
Inverter
Solar Solar charger Load
Converter
Battery
Compare with UPS or normal inverter, INVERTER combines a solar charger inside. Solar charger can be
a supplement for battery when there is not grid or for saving energy purpose. And with the solar charger,
the inverter can derive more working modes than UPS. The detail you can refer to our user manual.
3
V201505A
1.3 Overview the inverter
PWM:
Control board
Main board
AVR
transfomer
SCC board
AVR board
PAR board
MPPT:
Control board
Main board
AVR
transfomer
SCC board
PAR board
AVR board
4
V201505A
2. Troubleshooting
2.1 How to do
When the inverter was faulty, normally there are two main symptoms:
No display at all;
Fault code or warning code on the LCD;
When the fault occurred, please help to record the fault information and follow “How to check” of part 2.2
to check the inverter, then feedback the checking result to the service center. It will be very helpful for
solving the problem as soon as possible.
2.2 Fault condition
Note:
When opening the top cover, please check if any obviously damaged parts exist ?
When removing the main board out, please check if obviously damaged parts exist?
2.2.1. Not working at all/ No display
Description The inverter couldn’t startup completely.
Possible reason There may be something wrong with SPS module.
How to check 1. Firstly, please measure the resistor between BAT+ and BAT-. If it is not shorted,
only connect the inverter with battery, and press “ON” button, could the inverter
startup?
2. If the first step is NG, please disconnect all the wires and open the top cover, and
then take the main board outside by following part 4.
3. Check the main board by following “3.7”
How to solve Repair the main board or replace it directly.
2.2.2. 01 fault
Description Fan abnormal.
Possible reason There was something wrong with fans or the fan driver has something wrong.
How to check Replace the fans first, if the issue still exist, please check the main board by
following “3.11”.
How to solve Replace the fan or repair the main board.
2.2.3. 02 fault
Description Over temperature.
Possible reason The NTC is broken.
How to check Check the inverter by following “3.10”
How to solve Replace the NTC and resistors.
2.2.4. 03 fault
Description Battery voltage is too high.
Possible reason Reason1: The reverse mosfet was damaged
5
V201505A
Reason2: Firmware bug.
Reason3: TX9 has something wrong.
How to check When the fault happened, please read the battery voltage in the LCD first, and
compare with the actual battery voltage.
Reason1: Check the inverter by following “3.8”
Reason3: Check the inverter by following “TX9 in 3.7”
How to solve Replace the mosfet or the main board if the reason is 1 or 3.
Update the firmware if the reverse mosfet was OK.
2.2.5. 06 fault
Description Output voltage is too high
Possible reason It depends; maybe the inverter module had something wrong.
How to check 1. Startup the inverter only with battery, will the fault come out again? If not, please
provide the situation when will the fault occur?
2. If the fault repeated even without load, please check the main board by following
“3.4”
How to solve Replace the main board.
2.2.6. 08 fault
Description Bus voltage is too high
Possible reason Firmware bug.
How to check Restart the inverter, will the fault repeat?
How to solve Update the firmware
2.2.7. 09 fault
Description Bus soft start fails.
Possible reason DC-DC module was damaged or bus soft start module was damaged.
How to check 1. Check the main board by following “3.1.2; 3.2.1; 3.4.1”;
2. Check the main board by following “3.5”.
How to solve Repair the main board or replace it directly.
2.2.8. 52 fault
Description Bus voltage is too low
Possible reason It depends; maybe the inverter module had something wrong.
How to check 1. Startup the inverter only with battery, will the fault come out again? If not, please
provide the situation when will the fault occur?
2. If the fault repeated even without load, please check the main board by following
“3.1.2 and 3.4”
How to solve Repair the main board or replace it directly.
6
V201505A
2.2.9. 53 fault
Description Inverter soft start failed.
Possible reason
How to check 1. Startup the inverter only with battery, will the fault come out again? If not, please
provide the situation when will the fault occur?
2. Connect the grid and battery, could the inverter charge the battery?
3. If step 1 and 2 are both not OK, please check the main board by following “3.1.2,
3.2.1 and 3.4.1”.
How to solve Replace the main board.
2.2.10. 56 fault
Description Battery couldn’t be detected.
Possible reason Wire connection or fuse was burnt.
How to check 1. Check the wire connection, the priority of the battery cable;
2. Check the main board by following “3.1.1 and 3.1.2”.
How to solve Repair the main board or replace it directly.
2.2.11. 57 fault
Description Current sensor is abnormal.
Possible reason The control board was damaged.
How to check Check the control board by following “3.9”.
How to solve Replace the control board.
2.2.12. 58 fault
Description Output voltage is too low.
Possible reason
How to check 1. Startup the inverter only with battery, will the fault come out again? If not, please
provide the situation when will the fault occur?
2. Connect the grid and battery, could the inverter charge the battery?
3. If step 1 and 2 are both not OK, please check the main board by following “3.1.2,
3.2.1 and 3.4.1”.
How to solve Replace the main board.
2.2.13. 72 fault
Description Current sensor is abnormal.
Possible reason The control board was damaged.
How to check Check the control board by following “3.9”.
How to solve Replace the control board.
2.2.14. 85 fault
7
V201505A
Description Current unbalance between the inverters when working in parallel mode.
Possible reason Most situations were due to the inappropriate wire connection
How to check Please help to check the AC input and output, the cables of two inverters should be
the same size and same length, and they should connect together to the
distributor. And please also check the connectors, have they been screwed tightly?
How to solve Modify the wire connection.
Test equipment:
Equipment Figures for example Parameter requirement
48V/200AH or 48V/200A
Battery or DC
source
or
80V/20A
PV simulator or
DC source or
230V/50Hz
AC source or
utility
or
The meter can measure DC and AC
voltage, current and frequency.
Power meter The voltage range should be 300V or
above. The current range should be more
than 30A.
5000VA/4000W
RCD load
8
V201505A
AC source
Power meter B
Battery
Power meter A
Load
PV simulate
9
V201505A
Please check the test result whether can meet with parameters listed as below:
Voltage Frequency Load% VA W
LCD 230V 50Hz 100% 5000VA 4000W
Power meter A 230V 50Hz N/A 5000VA 4000W
Note: The tolerance of voltage is about ±1%, and of frequency is about ±0.1Hz. Regarding load, it
depends on the actual load you have given. Please read the actual load from power meter, and then
compare the load values on LCD with the meter. The tolerance of power VA/W between LCD and power
meter is less than ±5%.
2.3.2 Line working mode test
2.3.2.1 Test and check
Switch off the load.
Set AC source to 230V/50Hz, and then turn on.
Wait for inverter transfer to line mode and charge the battery.
Check the LCD to confirm that inverter is working in line mode.
Record the charging current from power meter B.
2.3.2.2 Confirm
The LCD display is shown as below:
10
V201505A
Wait for 2 minutes; record the charging current from power meter B.
2.3.3.2 Confirm
The LCD display is shown as below:
11
V201505A
3. Checking and measuring guide
3.1 Check the battery side components
3.1.1. Fuse and capacitors
F1: 25-000148-00G (FUSE LITTELFUSE/142.5631.6202 200A 58V FAST 42*12) or 32-000065-00G
(BUS BAR COPPER 42*12*0.6)
C12/C13/C8/C9: 15-000072-00G (C-AL 3300UF 63V M RAD BULK 7.5 105℃ 18*45.5)
12
V201505A
3.1.2. Power devices
DC/DC MOSFET: Q11/Q17/Q20/Q24 & Q38/Q21/Q22/Q12 & Q13/Q18/Q23/Q19 & Q40/Q26/Q25/Q14
ALL of the mosfet are 11-320110-00G (MOSFET IR/IRFB3307ZPBF 120A 75V N BULK TO-220).*
*: In the new version, they will be 11-320138-00G (MOSFET TI/CSD19505KCS 201A 80V N BULK
TO-220) or 11-320117-00G (MOSFET IR/IRFB3077 210A 75V N BULK TO-220).
Parts Attribute Reference values Failure status
All: IRFB3307ZPBF Resistor1 GS: 11.7k Short or explosion
GD: 250k
DS: OL
Diode SD: 0.43V
DS: OL
Note1: When you use the multimeter to measure the resistor of the transistor, because of the capacitor in
the circuit, it will cause the changing of the values when you measure the DS and GD. So we recommend
you measure the diode forward voltage of SD, and the resistor of GS. These two values can reflect the
situation of the transistor more correctly.
Note: If one or more of them were damaged, please replace all of them.
Note: For 4K, Q19/Q24/Q38/Q40 is N/A.
13
V201505A
Use multimeter to measure each resistor, find the burnt resistors and replace them; don’t need to replace
them all.
14
V201505A
Parts Attribute Reference values Failure status
All: 22ohm Resistor 22 ohm Open or other values
If the resistors need to be replaced, please also check the driver transistors and control IC.
The Q46and Q48 are 11-300012-00G (TR UTC/2SC2655 2A 50V NPN TAP TO-92)
The Q47and Q49 are 11-300005-00G (TR UTC/A1020 2A 50V PNP TAP TO-92NL)
The Q41and Q43 are 11-300012-00G (TR UTC/2SC2655 2A 50V NPN TAP TO-92)
The Q15and Q16 are 11-300005-00G (TR UTC/A1020 2A 50V PNP TAP TO-92NL)
Parts Attribute Reference values Failure status
Q46/Q48/Q41/Q43 Resistor BE: 420k Short or explosion
BC: 420k
CE: 30k
Diode BE: 0.6V
BC: 0.6V
CE: 2.3V
Q47/Q49/Q15/Q16 Resistor BE: 420k Short or explosion
BC: 420k
CE: 1.2k
Diode BE: 0.6V
BC: 2.6V
CE: 0.2V
15
V201505A
The Q54and Q56 are 11-400011-00G (TR UTC/2SD1624 2A 50V NPN SOT-89)
The Q55and Q57 are 11-400010-00G (TR UTC/2SA1020 3A 50V PNP SOT-89)
The Q51and Q52 are 11-400011-00G (TR UTC/2SD1624 2A 50V NPN SOT-89)
The Q50and Q53 are 11-400010-00G (TR UTC/2SA1020 3A 50V PNP SOT-89)
Parts Attribute Reference values Failure status
Q54/Q56/Q51/Q52 Resistor BE: 12k Short or explosion
BC: 260k
CE: OL
Diode BE: 0.6V
BC: 0.6V
CE: OL
Q55/Q57/Q50/Q53 Resistor BE: 12k Short or explosion
BC: OL
CE: 277k
Diode BE: 0.6V
BC: OL
CE: 1.09V
16
V201505A
The Q60and Q61 are 11-420007-00G (MOSFET UTC/UT3404G 5.8A 30V NPN SOT-23 SMD)
Parts Attribute Reference values Failure status
Q60/Q61 Resistor GS: 5.637k Short or explosion
GD: 12k
DS: 35k
Diode SD: 0.184V
DS: 1.2V
17
V201505A
Note: If you are not sure about these components, we recommend you replacing them all.
G C E
ALL of the IGBTs are 11-330035-00G (IGBT IRGP/4063DPBF 48A 600V NPN BULK TO-247) or
11-330095-00G (IGBT IR/IRGP4750DPBF 50A 650V N BULK TO-247)
Parts Attribute Reference values Failure status
Q27/Q28/Q29/Q30 Resistor1 GE: 22 ohm Short or explosion
GC: 181k
CE: 1 Meg
Diode EC: 0.37V
CE: OL
Note1: When you use the multimeter to measure the resistor of the transistor, because of the capacitor in
the circuit, it will cause the changing of the values when you measure the CE and GE. So we recommend
you measure the diode forward voltage of EC, and the resistor of GE. These two values can reflect the
situation of the transistor more correctly.
Note: If one or more of them were damaged, please replace all of them.
18
V201505A
Meanwhile, we also need to check the driver tubes of these power tubes.
R91/R102/R96/R101: 14-110022-00G (RES CHIP TF 1/4W 22 F 1206)
R90/R99/R94/R97: 14-110000-00G (RES CHIP TF 1/4W 0 F 1206)
D32/D35/D33/D34: 11-210001-00G (D PAJ 1N4148W 0.15A 75V SMD)
-
+
19
V201505A
3.3 Check the buck circuit
3.3.1. Power devices
BUCK MOSFET and Diode: Q31/Q32/D13
G E/S
- +
C/D
The Q31and Q32 are 11-320049-00G (MOSFET ST/STW45NM60 45A 600V N BULK TO-247) or
11-330095-00G (IGBT IR/IRGP4750DPBF 50A 650V N BULK TO-247)
The D13 is 11-200007-00G (D APT/30DQ60BG 30A 600V UFST RAD TO-247 BULK) or 11-200167-00G
(D FSC/FFH30S60S 30A 600V UFST RAD TO-247 BULK)*
*: In the new version (Main board: 71-500449-xxG), it will be 11-200032-00G D FC/RHRP1560 15A 600V
UFST RAD BULK.
Parts Attribute Reference values Failure status
Q31/Q32 Resistor GS or GE: 23.5k Short or explosion
GD or GC: 273k
DS or CE: 800k
Diode SD or CE: 0.44V
DS or EC: OL
D13 Resistor + to -: 168k
- to +: OL
Diode + to -: 0.36V
- to +: OL
20
V201505A
Note: If one or more of them were damaged, please replace all of them.
21
V201505A
3.4 Check the INV full bridge
3.4.1. Power devices
INV IGBT: QA1/QC1/QB2/QD2
G E
C
All of the IGBT are 11-330080-00G (IGBT IR/IRGP4066D-EPBF 75A 600V N BULK TO-247)
Parts Attribute Reference values Failure status
QA1/QC1/QB2/QD2 Resistor GE: 23k Short or explosion
GC: 235k
CE: 900k
Diode EC: 0.4V
CE: OL
Note1: If one or more of them were damaged, please replace all of them.
Note2: For 4K, QA1~QD2 is 11-330035-00G (IGBT IRGP/4063DPBF 48A 600V NPN BULK TO-247)
3.4.2. Drivers
R48/R144/R140/R137/R139/R145/R150/R152: 14-110047-00G (RES CHIP TF 1/4W 47 F 1206)
D5/D6/D12/D16: 11-210001-00G (D PAJ 1N4148W 0.15A 75V SMD)
22
V201505A
-
+
Parts Attribute Reference values Failure status
R48/R144/R140/R137 Resistor 47 ohm Open or other values
R139/R145/R150/R152
D5/D6/D12/D161 Resistor + to -: 240k Short or explosion
- to +: OL
Diode + to -: 0.6V
- to +: OL
Note 1: When test the diode; please remove the R139/R145/R150/R152 from the board, or the test result
is not right.
Optocoupler: U1/U2/U3/U4/U12
ALL of the optocoupler are 11-140006-00G(IC PHO AVAGO/T350-560E DIP-8 8/300 MIL SMD)
Parts Attribute Reference values Failure status
U1/U2/U3/U4/U12 Resistor PIN8 TO PIN5: 2k Short or explosion
PIN7 TO PIN5: 2k
23
V201505A
3.5 Check the bus soft start circuit (TX2: Especially for 09 fault)
D73: 11-200026-00G (D PAJ/UF202 2A 200V UFST AXI TAP)
Q6: 11-320050-00G (MOSFET IR/IRF840 8A 500V N BULK TO-220)
R251: 14-600005-00G (RES 2W 0.62 J RAD N-IND BULK)
D65: 11-200023-00G (D FC/RHRP8120 8A 1200V UFST RAD BULK)
24
V201505A
Note: If R245 is damaged, please replace U16 together.
U16: 11-104003-00G (IC PWM CNTL UTC/UC3845A 8P/SOP-8 SMD)
25
V201505A
TX2: 41-070186-01G (TX 15:200:15 FER EEL16)
26
V201505A
S
D
G
- +
8
Note: If R233 is damaged, please replace U15 together.
U15: 11-104003-00G (IC PWM CNTL UTC/UC3845A 8P/SOP-8 SMD)
Parts Attribute Reference values Failure status
D17/D18/D20/D21 Resistor + to -: 270k Short or explosion
- to +: 800k
Diode + to -: 0.57V
- to +: OL
Q37 Resistor GS: 29k Short or explosion
GD: 336k
27
V201505A
DS: 550k
Diode SD: 0.5V
DS: OL
R233 Resistor 22 ohm Open or other values
U15 Resistor PIN7 TO PIN5: 42k Short or explosion
PIN6 TO PIN5: 30k
D54: 11-200093-00G
(D ON/MUR460RLG
4A 600V UFST RAD
AXI DO-201AD TAP)
28
V201505A
R126/R217: 14-110010-00G (RES CHIP TF 1/4W 10 F 1206)
D51: 11-210001-00G (D PAJ 1N4148W 0.15A 75V SMD)
29
V201505A
- to +: OL
Diode + to -: 0.53V
- to +: OL
Q36 Resistor GS: 16k Short or explosion
GD: OL
DS: OL
Diode SD: 0.52V
DS: OL
R205/R215 Resistor 0.15 ohm Open or other values
D54 Resistor + to -: 2.5k Short or explosion
- to +: 3.9k
Diode + to -: 0.44V
- to +: 0.68V
D67 Resistor + to -: 100k Short or explosion
- to +: 500k
Diode + to -: 0.43V
- to +: 2.6V
D70 Resistor + to -: 235.2k
- to +: 2 Meg
Diode + to -: 0.43V
- to +: 2.7V
R126/R217 Resistor 10 ohm Open or other values
D51 Resistor + to -: 240k
- to +: OL
Diode + to -: 0.6V
- to +: OL
U10 Resistor PIN7 TO PIN5: 2k Short or explosion
PIN6 TO PIN5: 16k
30
V201505A
TX9: 41-070194-01G (TX 5:5:5:3:
1:6 FER EE28)
TX9
PIN12 PIN11
31
V201505A
Parts Attribute Reference values Failure status
PV- to BAT- Resistor >10k Short
32
V201505A
3.9 Check the current sharing module of control board
33
V201505A
The pin definition of D24 and D25 shows as below:
34
V201505A
Parts Attribute Reference values Failure status
R272 Resistor 700~750 ohm Short or other values
NTC3_HS1 in CN8 Resistor 4~6k ohm Short or other values
NTC3_HS1 separately Resistor 15k ohm Short or other values
Note: Please plug out the NTC from CN8, and measure the resistance of NTC directly. The result may not
reflect the real value of the NTC if you measure the value on the main board. We also provide the value
when NTC is plugged on the main board for reference.
If you are not convenient to test the resistance, you can unplug the NTC, and test the inverter again. If the
fault doesn’t happen again, it means that this NTC is wrong.
35
V201505A
Transformer
The NTC is located as below:
If the NTCs on the DC-DC and INV heatsink are OK, it means that NTC1 is wrong. You can also remove
NTC1 from the main board for checking.
36
V201505A
INV heatsink
The NTC is located as below:
If you are not convenient to test the resistance, you can unplug the NTC, and test the inverter again. If the
fault doesn’t happen again, it means that this NTC is wrong.
37
V201505A
3.11 Check the fan driver on the main board
The parts of fan driver are marked as below:
38
V201505A
4. Assembling guide
Remove the
screws of the
panel cover.
Remove the
screws of top
cover.
39
V201505A
Remove the
isolation paper.
Remove the
parallel power
board if the
inverter has.
And remove
the plastic nails
on the air flow
paper.
40
V201505A
Remove the
cable on the
control board.
41
V201505A
Remove the
control board
Remove the
SCC board.
42
V201505A
Remove I/P
and O/P
cables.
Output N
Input N
Output L
Input L
Remove the
cable from
main board to
AVR board.
Blue cable
Brown
cable
43
V201505A
Remove
terminal panel.
Remove the
other cables
44
V201505A
Remove the
screw on the
main board.
45
V201505A
Take out the
main board,
and then you
can put the
new main
board in.
46
V201505A